CA2502498C - Treatment of smelting by-products - Google Patents
Treatment of smelting by-products Download PDFInfo
- Publication number
- CA2502498C CA2502498C CA 2502498 CA2502498A CA2502498C CA 2502498 C CA2502498 C CA 2502498C CA 2502498 CA2502498 CA 2502498 CA 2502498 A CA2502498 A CA 2502498A CA 2502498 C CA2502498 C CA 2502498C
- Authority
- CA
- Canada
- Prior art keywords
- residue
- spent
- spent potliner
- kiln
- potliner
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired - Lifetime
Links
- 238000003723 Smelting Methods 0.000 title claims abstract description 9
- 239000006227 byproduct Substances 0.000 title description 7
- 238000000034 method Methods 0.000 claims abstract description 42
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims abstract description 24
- 229910052500 inorganic mineral Inorganic materials 0.000 claims abstract description 23
- 239000011707 mineral Substances 0.000 claims abstract description 23
- 239000004411 aluminium Substances 0.000 claims abstract description 21
- 229910052782 aluminium Inorganic materials 0.000 claims abstract description 21
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims abstract description 21
- 239000007789 gas Substances 0.000 claims abstract description 21
- 238000002156 mixing Methods 0.000 claims abstract description 20
- 238000006243 chemical reaction Methods 0.000 claims abstract description 17
- 239000000126 substance Substances 0.000 claims abstract description 10
- 238000010438 heat treatment Methods 0.000 claims abstract description 7
- 238000005054 agglomeration Methods 0.000 claims description 9
- 230000002776 aggregation Effects 0.000 claims description 9
- 150000001875 compounds Chemical class 0.000 claims description 7
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 claims description 6
- 239000001301 oxygen Substances 0.000 claims description 6
- 229910052760 oxygen Inorganic materials 0.000 claims description 6
- 238000012545 processing Methods 0.000 claims description 2
- 239000000203 mixture Substances 0.000 claims 1
- 239000000463 material Substances 0.000 description 31
- 239000000047 product Substances 0.000 description 22
- 229910052799 carbon Inorganic materials 0.000 description 21
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 18
- 239000003570 air Substances 0.000 description 18
- 235000010755 mineral Nutrition 0.000 description 17
- XFXPMWWXUTWYJX-UHFFFAOYSA-N Cyanide Chemical compound N#[C-] XFXPMWWXUTWYJX-UHFFFAOYSA-N 0.000 description 15
- QGZKDVFQNNGYKY-UHFFFAOYSA-N Ammonia Chemical compound N QGZKDVFQNNGYKY-UHFFFAOYSA-N 0.000 description 12
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 10
- VNWKTOKETHGBQD-UHFFFAOYSA-N methane Chemical compound C VNWKTOKETHGBQD-UHFFFAOYSA-N 0.000 description 10
- CURLTUGMZLYLDI-UHFFFAOYSA-N Carbon dioxide Chemical compound O=C=O CURLTUGMZLYLDI-UHFFFAOYSA-N 0.000 description 9
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 9
- 238000004255 ion exchange chromatography Methods 0.000 description 9
- XEEYBQQBJWHFJM-UHFFFAOYSA-N iron Substances [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 9
- 229910052742 iron Inorganic materials 0.000 description 9
- 239000011734 sodium Substances 0.000 description 8
- 229910052708 sodium Inorganic materials 0.000 description 8
- 239000000428 dust Substances 0.000 description 7
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 description 6
- 238000004458 analytical method Methods 0.000 description 6
- 238000001479 atomic absorption spectroscopy Methods 0.000 description 6
- 229910002092 carbon dioxide Inorganic materials 0.000 description 6
- 239000011651 chromium Substances 0.000 description 6
- 150000002222 fluorine compounds Chemical class 0.000 description 6
- 239000000446 fuel Substances 0.000 description 6
- 230000001939 inductive effect Effects 0.000 description 6
- 239000012633 leachable Substances 0.000 description 6
- 239000011572 manganese Substances 0.000 description 6
- 238000004519 manufacturing process Methods 0.000 description 6
- 238000006386 neutralization reaction Methods 0.000 description 6
- 238000004611 spectroscopical analysis Methods 0.000 description 6
- DGAQECJNVWCQMB-PUAWFVPOSA-M Ilexoside XXIX Chemical compound C[C@@H]1CC[C@@]2(CC[C@@]3(C(=CC[C@H]4[C@]3(CC[C@@H]5[C@@]4(CC[C@@H](C5(C)C)OS(=O)(=O)[O-])C)C)[C@@H]2[C@]1(C)O)C)C(=O)O[C@H]6[C@@H]([C@H]([C@@H]([C@H](O6)CO)O)O)O.[Na+] DGAQECJNVWCQMB-PUAWFVPOSA-M 0.000 description 5
- 239000003245 coal Substances 0.000 description 5
- 238000001784 detoxification Methods 0.000 description 5
- 229910052751 metal Inorganic materials 0.000 description 5
- 239000002184 metal Substances 0.000 description 5
- 239000002994 raw material Substances 0.000 description 5
- 239000000523 sample Substances 0.000 description 5
- 239000002699 waste material Substances 0.000 description 5
- UFHFLCQGNIYNRP-UHFFFAOYSA-N Hydrogen Chemical compound [H][H] UFHFLCQGNIYNRP-UHFFFAOYSA-N 0.000 description 4
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 description 4
- 239000005864 Sulphur Substances 0.000 description 4
- HSFWRNGVRCDJHI-UHFFFAOYSA-N alpha-acetylene Natural products C#C HSFWRNGVRCDJHI-UHFFFAOYSA-N 0.000 description 4
- 229910021529 ammonia Inorganic materials 0.000 description 4
- 239000011449 brick Substances 0.000 description 4
- 239000011575 calcium Substances 0.000 description 4
- 229910052791 calcium Inorganic materials 0.000 description 4
- 239000004568 cement Substances 0.000 description 4
- 239000001257 hydrogen Substances 0.000 description 4
- 229910052739 hydrogen Inorganic materials 0.000 description 4
- 239000010703 silicon Substances 0.000 description 4
- 229910052710 silicon Inorganic materials 0.000 description 4
- VYZAMTAEIAYCRO-UHFFFAOYSA-N Chromium Chemical compound [Cr] VYZAMTAEIAYCRO-UHFFFAOYSA-N 0.000 description 3
- KRHYYFGTRYWZRS-UHFFFAOYSA-M Fluoride anion Chemical compound [F-] KRHYYFGTRYWZRS-UHFFFAOYSA-M 0.000 description 3
- PWHULOQIROXLJO-UHFFFAOYSA-N Manganese Chemical compound [Mn] PWHULOQIROXLJO-UHFFFAOYSA-N 0.000 description 3
- ZLMJMSJWJFRBEC-UHFFFAOYSA-N Potassium Chemical compound [K] ZLMJMSJWJFRBEC-UHFFFAOYSA-N 0.000 description 3
- HEMHJVSKTPXQMS-UHFFFAOYSA-M Sodium hydroxide Chemical class [OH-].[Na+] HEMHJVSKTPXQMS-UHFFFAOYSA-M 0.000 description 3
- 238000004847 absorption spectroscopy Methods 0.000 description 3
- 229910021502 aluminium hydroxide Inorganic materials 0.000 description 3
- WNROFYMDJYEPJX-UHFFFAOYSA-K aluminium hydroxide Chemical compound [OH-].[OH-].[OH-].[Al+3] WNROFYMDJYEPJX-UHFFFAOYSA-K 0.000 description 3
- 150000001450 anions Chemical class 0.000 description 3
- 229910052787 antimony Inorganic materials 0.000 description 3
- WATWJIUSRGPENY-UHFFFAOYSA-N antimony atom Chemical compound [Sb] WATWJIUSRGPENY-UHFFFAOYSA-N 0.000 description 3
- 229910052785 arsenic Inorganic materials 0.000 description 3
- RQNWIZPPADIBDY-UHFFFAOYSA-N arsenic atom Chemical compound [As] RQNWIZPPADIBDY-UHFFFAOYSA-N 0.000 description 3
- 230000009286 beneficial effect Effects 0.000 description 3
- 229910052790 beryllium Inorganic materials 0.000 description 3
- 230000033558 biomineral tissue development Effects 0.000 description 3
- 230000015572 biosynthetic process Effects 0.000 description 3
- 229910052793 cadmium Inorganic materials 0.000 description 3
- 239000000460 chlorine Substances 0.000 description 3
- 229910052804 chromium Inorganic materials 0.000 description 3
- 239000010941 cobalt Substances 0.000 description 3
- 229910017052 cobalt Inorganic materials 0.000 description 3
- 230000000694 effects Effects 0.000 description 3
- 238000010304 firing Methods 0.000 description 3
- 230000004927 fusion Effects 0.000 description 3
- 229910001679 gibbsite Inorganic materials 0.000 description 3
- 239000010439 graphite Substances 0.000 description 3
- 229910002804 graphite Inorganic materials 0.000 description 3
- 229910052748 manganese Inorganic materials 0.000 description 3
- 150000001247 metal acetylides Chemical class 0.000 description 3
- 150000004767 nitrides Chemical class 0.000 description 3
- 229910052757 nitrogen Inorganic materials 0.000 description 3
- 238000007500 overflow downdraw method Methods 0.000 description 3
- 239000011591 potassium Substances 0.000 description 3
- 229910052700 potassium Inorganic materials 0.000 description 3
- 239000011819 refractory material Substances 0.000 description 3
- SPVXKVOXSXTJOY-UHFFFAOYSA-N selane Chemical compound [SeH2] SPVXKVOXSXTJOY-UHFFFAOYSA-N 0.000 description 3
- 239000011669 selenium Substances 0.000 description 3
- 239000000377 silicon dioxide Substances 0.000 description 3
- 239000011573 trace mineral Substances 0.000 description 3
- 235000013619 trace mineral Nutrition 0.000 description 3
- 229910052720 vanadium Inorganic materials 0.000 description 3
- LEONUFNNVUYDNQ-UHFFFAOYSA-N vanadium atom Chemical compound [V] LEONUFNNVUYDNQ-UHFFFAOYSA-N 0.000 description 3
- 229910014813 CaC2 Inorganic materials 0.000 description 2
- VEXZGXHMUGYJMC-UHFFFAOYSA-M Chloride anion Chemical compound [Cl-] VEXZGXHMUGYJMC-UHFFFAOYSA-M 0.000 description 2
- NINIDFKCEFEMDL-UHFFFAOYSA-N Sulfur Chemical compound [S] NINIDFKCEFEMDL-UHFFFAOYSA-N 0.000 description 2
- 239000000654 additive Substances 0.000 description 2
- 239000001569 carbon dioxide Substances 0.000 description 2
- 239000003575 carbonaceous material Substances 0.000 description 2
- 230000015556 catabolic process Effects 0.000 description 2
- 238000001816 cooling Methods 0.000 description 2
- 230000006378 damage Effects 0.000 description 2
- 239000003792 electrolyte Substances 0.000 description 2
- 230000007613 environmental effect Effects 0.000 description 2
- 125000002534 ethynyl group Chemical group [H]C#C* 0.000 description 2
- 239000002360 explosive Substances 0.000 description 2
- 239000000383 hazardous chemical Substances 0.000 description 2
- 239000010423 industrial mineral Substances 0.000 description 2
- 239000011344 liquid material Substances 0.000 description 2
- 239000007791 liquid phase Substances 0.000 description 2
- 230000014759 maintenance of location Effects 0.000 description 2
- 150000002825 nitriles Chemical class 0.000 description 2
- 229910000069 nitrogen hydride Inorganic materials 0.000 description 2
- 239000002245 particle Substances 0.000 description 2
- 238000002360 preparation method Methods 0.000 description 2
- 238000005204 segregation Methods 0.000 description 2
- 238000004513 sizing Methods 0.000 description 2
- 229910001220 stainless steel Inorganic materials 0.000 description 2
- 239000010935 stainless steel Substances 0.000 description 2
- OYPRJOBELJOOCE-UHFFFAOYSA-N Calcium Chemical compound [Ca] OYPRJOBELJOOCE-UHFFFAOYSA-N 0.000 description 1
- ZAMOUSCENKQFHK-UHFFFAOYSA-N Chlorine atom Chemical compound [Cl] ZAMOUSCENKQFHK-UHFFFAOYSA-N 0.000 description 1
- CDBYLPFSWZWCQE-UHFFFAOYSA-L Sodium Carbonate Chemical compound [Na+].[Na+].[O-]C([O-])=O CDBYLPFSWZWCQE-UHFFFAOYSA-L 0.000 description 1
- 229910000831 Steel Inorganic materials 0.000 description 1
- CKUAXEQHGKSLHN-UHFFFAOYSA-N [C].[N] Chemical class [C].[N] CKUAXEQHGKSLHN-UHFFFAOYSA-N 0.000 description 1
- 230000000996 additive effect Effects 0.000 description 1
- 239000012080 ambient air Substances 0.000 description 1
- 238000007664 blowing Methods 0.000 description 1
- BDOSMKKIYDKNTQ-UHFFFAOYSA-N cadmium atom Chemical compound [Cd] BDOSMKKIYDKNTQ-UHFFFAOYSA-N 0.000 description 1
- AXCZMVOFGPJBDE-UHFFFAOYSA-L calcium dihydroxide Chemical compound [OH-].[OH-].[Ca+2] AXCZMVOFGPJBDE-UHFFFAOYSA-L 0.000 description 1
- 239000000920 calcium hydroxide Substances 0.000 description 1
- 235000011116 calcium hydroxide Nutrition 0.000 description 1
- 229910001861 calcium hydroxide Inorganic materials 0.000 description 1
- 238000005266 casting Methods 0.000 description 1
- 239000003518 caustics Substances 0.000 description 1
- 239000003795 chemical substances by application Substances 0.000 description 1
- 229910052801 chlorine Inorganic materials 0.000 description 1
- 238000004891 communication Methods 0.000 description 1
- 229910001610 cryolite Inorganic materials 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 230000002708 enhancing effect Effects 0.000 description 1
- 238000004880 explosion Methods 0.000 description 1
- 239000002803 fossil fuel Substances 0.000 description 1
- 239000007792 gaseous phase Substances 0.000 description 1
- 231100001261 hazardous Toxicity 0.000 description 1
- 239000003077 lignite Substances 0.000 description 1
- 150000002736 metal compounds Chemical class 0.000 description 1
- 229910044991 metal oxide Inorganic materials 0.000 description 1
- 150000004706 metal oxides Chemical class 0.000 description 1
- 150000002739 metals Chemical class 0.000 description 1
- VUZPPFZMUPKLLV-UHFFFAOYSA-N methane;hydrate Chemical compound C.O VUZPPFZMUPKLLV-UHFFFAOYSA-N 0.000 description 1
- 239000003921 oil Substances 0.000 description 1
- 230000003647 oxidation Effects 0.000 description 1
- 238000007254 oxidation reaction Methods 0.000 description 1
- 239000002006 petroleum coke Substances 0.000 description 1
- 239000003209 petroleum derivative Substances 0.000 description 1
- 230000000750 progressive effect Effects 0.000 description 1
- 239000011253 protective coating Substances 0.000 description 1
- 230000001681 protective effect Effects 0.000 description 1
- 238000010791 quenching Methods 0.000 description 1
- 230000000171 quenching effect Effects 0.000 description 1
- 238000011084 recovery Methods 0.000 description 1
- 239000004576 sand Substances 0.000 description 1
- 230000035939 shock Effects 0.000 description 1
- 235000011121 sodium hydroxide Nutrition 0.000 description 1
- 239000007787 solid Substances 0.000 description 1
- 239000007790 solid phase Substances 0.000 description 1
- 239000010959 steel Substances 0.000 description 1
- 238000003860 storage Methods 0.000 description 1
- 238000010408 sweeping Methods 0.000 description 1
- 238000012360 testing method Methods 0.000 description 1
- 238000004448 titration Methods 0.000 description 1
Classifications
-
- A—HUMAN NECESSITIES
- A62—LIFE-SAVING; FIRE-FIGHTING
- A62D—CHEMICAL MEANS FOR EXTINGUISHING FIRES OR FOR COMBATING OR PROTECTING AGAINST HARMFUL CHEMICAL AGENTS; CHEMICAL MATERIALS FOR USE IN BREATHING APPARATUS
- A62D3/00—Processes for making harmful chemical substances harmless or less harmful, by effecting a chemical change in the substances
- A62D3/30—Processes for making harmful chemical substances harmless or less harmful, by effecting a chemical change in the substances by reacting with chemical agents
- A62D3/38—Processes for making harmful chemical substances harmless or less harmful, by effecting a chemical change in the substances by reacting with chemical agents by oxidation; by combustion
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B09—DISPOSAL OF SOLID WASTE; RECLAMATION OF CONTAMINATED SOIL
- B09B—DISPOSAL OF SOLID WASTE NOT OTHERWISE PROVIDED FOR
- B09B3/00—Destroying solid waste or transforming solid waste into something useful or harmless
- B09B3/40—Destroying solid waste or transforming solid waste into something useful or harmless involving thermal treatment, e.g. evaporation
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B09—DISPOSAL OF SOLID WASTE; RECLAMATION OF CONTAMINATED SOIL
- B09B—DISPOSAL OF SOLID WASTE NOT OTHERWISE PROVIDED FOR
- B09B3/00—Destroying solid waste or transforming solid waste into something useful or harmless
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B09—DISPOSAL OF SOLID WASTE; RECLAMATION OF CONTAMINATED SOIL
- B09B—DISPOSAL OF SOLID WASTE NOT OTHERWISE PROVIDED FOR
- B09B3/00—Destroying solid waste or transforming solid waste into something useful or harmless
- B09B3/20—Agglomeration, binding or encapsulation of solid waste
- B09B3/25—Agglomeration, binding or encapsulation of solid waste using mineral binders or matrix
- B09B3/29—Agglomeration, binding or encapsulation of solid waste using mineral binders or matrix involving a melting or softening step
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22B—PRODUCTION AND REFINING OF METALS; PRETREATMENT OF RAW MATERIALS
- C22B21/00—Obtaining aluminium
- C22B21/0015—Obtaining aluminium by wet processes
- C22B21/0023—Obtaining aluminium by wet processes from waste materials
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22B—PRODUCTION AND REFINING OF METALS; PRETREATMENT OF RAW MATERIALS
- C22B21/00—Obtaining aluminium
- C22B21/0038—Obtaining aluminium by other processes
- C22B21/0069—Obtaining aluminium by other processes from scrap, skimmings or any secondary source aluminium, e.g. recovery of alloy constituents
-
- A—HUMAN NECESSITIES
- A62—LIFE-SAVING; FIRE-FIGHTING
- A62D—CHEMICAL MEANS FOR EXTINGUISHING FIRES OR FOR COMBATING OR PROTECTING AGAINST HARMFUL CHEMICAL AGENTS; CHEMICAL MATERIALS FOR USE IN BREATHING APPARATUS
- A62D2101/00—Harmful chemical substances made harmless, or less harmful, by effecting chemical change
- A62D2101/40—Inorganic substances
-
- A—HUMAN NECESSITIES
- A62—LIFE-SAVING; FIRE-FIGHTING
- A62D—CHEMICAL MEANS FOR EXTINGUISHING FIRES OR FOR COMBATING OR PROTECTING AGAINST HARMFUL CHEMICAL AGENTS; CHEMICAL MATERIALS FOR USE IN BREATHING APPARATUS
- A62D2101/00—Harmful chemical substances made harmless, or less harmful, by effecting chemical change
- A62D2101/40—Inorganic substances
- A62D2101/45—Inorganic substances containing nitrogen or phosphorus
-
- A—HUMAN NECESSITIES
- A62—LIFE-SAVING; FIRE-FIGHTING
- A62D—CHEMICAL MEANS FOR EXTINGUISHING FIRES OR FOR COMBATING OR PROTECTING AGAINST HARMFUL CHEMICAL AGENTS; CHEMICAL MATERIALS FOR USE IN BREATHING APPARATUS
- A62D2101/00—Harmful chemical substances made harmless, or less harmful, by effecting chemical change
- A62D2101/40—Inorganic substances
- A62D2101/49—Inorganic substances containing halogen
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P10/00—Technologies related to metal processing
- Y02P10/20—Recycling
Landscapes
- Engineering & Computer Science (AREA)
- Chemical & Material Sciences (AREA)
- Environmental & Geological Engineering (AREA)
- Manufacturing & Machinery (AREA)
- Organic Chemistry (AREA)
- Metallurgy (AREA)
- Mechanical Engineering (AREA)
- Materials Engineering (AREA)
- General Health & Medical Sciences (AREA)
- General Chemical & Material Sciences (AREA)
- Business, Economics & Management (AREA)
- Emergency Management (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Toxicology (AREA)
- Physics & Mathematics (AREA)
- Health & Medical Sciences (AREA)
- Thermal Sciences (AREA)
- Processing Of Solid Wastes (AREA)
- Processing And Handling Of Plastics And Other Materials For Molding In General (AREA)
- Manufacture And Refinement Of Metals (AREA)
Abstract
A method of treating a spent potliner after use in an aluminium smelting process, the method comprising crushing and classifying the spent potliner, placing the classified and crushed spent potliner in a furnace at a temperature greater than 450 ~C, heating the spent potliner to a temperature greater than 450 ~C, mixing the heated spent potliner with water to produce reaction gases and residue, burning the reaction gases, mixing the residue with water in a well ventilated area for a period of weeks to cure the residue. The method also embraces blending the cured residue with other chemicals and minerals to provide specific mineral products.
Description
TITLE
TREATMENT OF SMELTING BY-PRODUCTS
INTRODUCTION
This invention relates to a method and apparatus of treating smelting by-products and in particular by-products of the aluminium smelting process.
BACKGROUND OF THE INVENTION
Production of aluminium metal typically involves the electrolytic reduction of alumina in cells or pots.
The electrolyte is made up of molten cryolite and other additives. The electrolyte is contained in a carbon and refractory lining in a steel potshell. The electrolytic cell includes a carbon anode with the lining of carbon coated in refractory material constituting the cathode.
Over time the effectiveness of the lining deteriorates and the lining of the pot is removed and then replaced with a new lining. The lining material that has been removed from the pot is referred to a spent potliner (SPL).
The nature of the aluminium reduction cell process results in the formation of various carbides and nitrides within the reduction cell contents (eg refractory lining and carbon cathode and anode).
As an example, at dull red heat and above, many metals such as calcium, aluminium and silicon readily form nitrides.
e.g. 2 Al + N2 - A12N2 At elevated temperatures, such metal oxides also react with carbon to form carbides.
TREATMENT OF SMELTING BY-PRODUCTS
INTRODUCTION
This invention relates to a method and apparatus of treating smelting by-products and in particular by-products of the aluminium smelting process.
BACKGROUND OF THE INVENTION
Production of aluminium metal typically involves the electrolytic reduction of alumina in cells or pots.
The electrolyte is made up of molten cryolite and other additives. The electrolyte is contained in a carbon and refractory lining in a steel potshell. The electrolytic cell includes a carbon anode with the lining of carbon coated in refractory material constituting the cathode.
Over time the effectiveness of the lining deteriorates and the lining of the pot is removed and then replaced with a new lining. The lining material that has been removed from the pot is referred to a spent potliner (SPL).
The nature of the aluminium reduction cell process results in the formation of various carbides and nitrides within the reduction cell contents (eg refractory lining and carbon cathode and anode).
As an example, at dull red heat and above, many metals such as calcium, aluminium and silicon readily form nitrides.
e.g. 2 Al + N2 - A12N2 At elevated temperatures, such metal oxides also react with carbon to form carbides.
2 A1203 + 9 C -* A14C3 + 6 CO
CaO + 3 C 4 CaC2 + CO
Under these conditions various carbon-nitrogen compounds are also produced in the forms of cyanides, both simple and complex forms.
The spent pot lining materials are also high in soda, and exhibit a pH in the vicinity of 11. This caustic soda is hygroscopic, and absorbs atmospheric water (humidity) which renders it mobile and so able to react with other components of the SPL stockpiles.
SPL is hazardous because of = Health and environmental hazards due to the presence of cyanide formed as a result of the reaction of nitrogen from air with the carbon lining.
= Reactive components that combine with water to give of ammonia, methane and hydrogen which presents a potential explosion hazard.
Disposal of SPL has been a problem for many years. In the past it was used as landfill but is now viewed as not environmentally friendly and thus its use as landfill has been banned in many countries. Consequently there have been many proposals to treat and handle SPL.
Most of these proposals create some residual waste which can be used as landfill.
This invention comes about from the appreciation that SPL is potentially valuable because of the calorific value of the carbon that it contains and the presence of minerals such as alumina, fluorides, silica and sodium that can be used in other industries.
It is these issues that have brought about the present invention.
SUMMARY OF INVENTION
In accordance with a first aspect of the present invention there is provided a method of treating a spent potliner after use in an aluminium smelting process, the method comprising crushing and classifying the spent potliner, placing the classified and crushed spent potliner in a furnace at a temperature greater than 450 C, heating the spent potliner to a temperature greater than 450 C, mixing the heated spent potliner with water to neutralize reactive compounds in the spent pot liner, and produce reaction gases and residue, burning the reaction gases, mixing the residue with water in a well ventilated area for a period of weeks to cure the residue, and blending the cured residue with other chemicals and minerals to provide useful mineral products.
Preferably the classified spent potliner is positioned in a rotary kiln into which air is introduced to ensure an oxygen enriched environment.
Preferably thermocouples are used to control the temperature of the kiln. In a preferred embodiment control jets of air are directed into the kiln to prevent agglomeration.
In accordance with a further aspect of the present invention there is provided a plant for processing spend potliners after use in the aluminium smelting process using the method described above.
DESCRIPTION OF THE DRAWINGS
Figure I is a block diagram that illustrates the flow chart to treat spent potliner, Figure 2 is a detailed flow chart of a detoxification process that forms part of the process illustrated in Figure 1, and Figure 3 is a schematic view of the process plant.
DESCRIPTION OF THE PREFERRED EMBODIMENT
An outline of the process for treating a spent potliner (SPL) of an aluminium smelter and producing a mineral product is shown in Figure 1 in three main steps, namely, (1) feed preparation in which the spent potliner is prepared crushed and classified, (2) detoxification in which the material is heated in the presence of air to destroy the presence of cyanide and mixed with water to cause neutralisation of reactive materials, and (3) a blending step in which treated SPL is mixed with other materials to produce mineral products of particular specifications which can be reused.
The feed preparation step involves recovery of the SPL material either from a storage depot or directly from the smelter pots, primary segregation of aluminium metal, carbon material and refractory materials and crushing size classification and secondary segregation of the materials into like categories. The crushing and classification steps are conventional to those skilled in this art.
Initially classified SPL is fed to the process plant. The sizing of the feed material can vary but -typically falls in the range 50 microns to 20mm.
The detoxification step involves a destruction of most of the cyanide through heat and then neutralisation 5 of the reactive compounds using water. The blending step producing mineral products takes place by blending the detoxified materials with other minerals and chemicals to achieve the desired product specification.
The detoxification process that is shown in detail in the flow summary of Figure 2 eliminates or substantially reduces the health environmental and explosive hazards that would otherwise be present in SPL.
The process involves a destruction of cyanide and the neutralisation of reactive compounds that give off acetylene, ammonia, methane, hydrogen and other gases. In the process described below it is understood that many of the requirements such as the heating temperatures and retention times would vary with different types of SPL
material.
The purpose of detoxofication is:
i) to convert as much as possible of the metal and metal compounds to inert oxides - eg.
4 Al + 3 02 - 2 A1203 A14C3 + 6 02 - 2 A1203 + 3 C02 4 Na4Fe (CN) 6 + 35 02 3 8 Na202 + 2 Fe203 + 24 CO2 + 12 N2 ii) destroy cyanides and combustible gases - eg.
Cyanide to carbon dioxide & nitrogen C2N2 + 2 02 4 2 CO2 + N2 Methane to carbon dioxide and water CH4 + 2 02 - CO2 + 2 H2O
Ammonia to nitrogen and water 4 NH3 + 3 02 4 2 N2 + 6 H2O
Hydrogen to water 2 H2 + 02 =3 2 H2O
The degree to which aluminium metal is oxidised depends upon the particle size, as a protective coating of the oxide inhibits instantaneous oxidation.
The neutralisation process involves the aqueous quenching of the hot product from the kiln to accelerate the reaction of any remaining metallic aluminium with its caustic environment. This part of the process also sees the reaction of any unoxidised carbides and nitrides as well as (protective) aluminium oxide. Eg.
2 Al + 2 OH- + 2 H2O 3 2 A102- + 3 H2 A14C3 + 12 H2O 3 4 Al(OH)3 + 3 CH4 CaC2 + 2 H2O -* Ca(OH)2 + C2H2 2 Al N + 6 H2O 3 2 Al(OH)3 + 2 NH3 Al(OH)3 + OH- -~ A102 - + 2 H2O
Gas evolution testing is carried out on the curing product to verify completion of explosive gas generation.
The potentially dangerous cyanide is destroyed by heating the SPL material in the presence of oxygen preferably to a range of between 750 C to 800 C. The heated SPL is held at that temperature for about 40 minutes. It is however important that the classified SPL
is not over heated to a temperature at which fluorides in the material enter the gaseous phase. This typically occurs at temperatures about 850 C and above.
A typical process plant is schematically shown in Figure 3. The classified SPL is initially fed to a belt feeder 10 which in turn feeds a bucket elevator 11 that transfers the SPL to a feed screw 12 that communicates with the inlet 13 of an elongate rotary kiln 20. A bag house dust collector 30 is in communication with the belt feeder and bucket elevator to control dust. The bag house dust collector would also include a source of cooling air 33. Agglomeration control air jets 21, 22 are positioned at either end of the kiln 20 and air is also fed to a probe support cooling jet 25. After leaving the kiln 30 the hot material is passed to a hydro-reaction mixer 40 where it is mixed with water. The product of the hydro-reaction mixer is then stock piled in a moist condition for curing in ambient air resulting in the detoxified material ready for reuse at the end of the ventilated curing step.
The classified SPL is heated to the required temperature in the rotary kiln 20 and the retention time in the material can be varied by varying the rotational speed of the kiln. The kiln 20 is usually fired by a fossil fuel burner and fuels could be natural petroleum gas, oil, pulverised coal or similar fuels. Additional air is introduced to the kiln to ensure that there is an oxygen rich environment in the kiln to support the chemical breakdown of cyanide. The temperature in the kiln is closely monitored with a number of thermocouple temperature probes located in the bed of material passing through the kiln 20. The temperature probes are mounted on a stainless steel tube through which air is blown from a compressed air source. Blowing air through the tube serves three purposes, namely (a) keeping the tube cool so that its structural integrity is maintained in the hot kiln environment, (b) keeping the signal cables from the thermocouple temperature probes cool in the otherwise hot environment in the kiln, and (c) introducing oxygen near the bed at points along the length of the kiln.
Some classified SPL materials have a tendency to agglomerate in the rotary kiln. This can occur at the feed end 13 when slightly damp material may build up and at points along the kiln where rings form as a result of heat causing certain minerals to enter a liquid phase.
Agglomeration is prevented by the agglomeration control jets 21, 22 which direct air from a compressed air source to points where agglomeration may occur. At the feed end 13 the jet of compressed air blows any material that sticks to the kiln lining off the kiln lining.
At points along the kiln where mineral in a liquid phase sticks to the kiln lining starting the formation of undesirable rings compressed air from an agglomeration control jet cools any liquid material returning it to a solid phase. The air jet 25 also cools the refractory lining at that location stopping the formation of liquid material against the hot refractory.
The agglomeration control jets 21, 22 provide additional free oxygen in the kiln to support the breakdown of cyanide.
The agglomeration control jets 21, 22 are mounted on a stainless steel pipe inside the kiln 20. The compressed air flowing through the pipe cools the pipe thus maintaining its structural integrity in the same manner as for the tube upon which the kiln temperature probes are mounted.
CaO + 3 C 4 CaC2 + CO
Under these conditions various carbon-nitrogen compounds are also produced in the forms of cyanides, both simple and complex forms.
The spent pot lining materials are also high in soda, and exhibit a pH in the vicinity of 11. This caustic soda is hygroscopic, and absorbs atmospheric water (humidity) which renders it mobile and so able to react with other components of the SPL stockpiles.
SPL is hazardous because of = Health and environmental hazards due to the presence of cyanide formed as a result of the reaction of nitrogen from air with the carbon lining.
= Reactive components that combine with water to give of ammonia, methane and hydrogen which presents a potential explosion hazard.
Disposal of SPL has been a problem for many years. In the past it was used as landfill but is now viewed as not environmentally friendly and thus its use as landfill has been banned in many countries. Consequently there have been many proposals to treat and handle SPL.
Most of these proposals create some residual waste which can be used as landfill.
This invention comes about from the appreciation that SPL is potentially valuable because of the calorific value of the carbon that it contains and the presence of minerals such as alumina, fluorides, silica and sodium that can be used in other industries.
It is these issues that have brought about the present invention.
SUMMARY OF INVENTION
In accordance with a first aspect of the present invention there is provided a method of treating a spent potliner after use in an aluminium smelting process, the method comprising crushing and classifying the spent potliner, placing the classified and crushed spent potliner in a furnace at a temperature greater than 450 C, heating the spent potliner to a temperature greater than 450 C, mixing the heated spent potliner with water to neutralize reactive compounds in the spent pot liner, and produce reaction gases and residue, burning the reaction gases, mixing the residue with water in a well ventilated area for a period of weeks to cure the residue, and blending the cured residue with other chemicals and minerals to provide useful mineral products.
Preferably the classified spent potliner is positioned in a rotary kiln into which air is introduced to ensure an oxygen enriched environment.
Preferably thermocouples are used to control the temperature of the kiln. In a preferred embodiment control jets of air are directed into the kiln to prevent agglomeration.
In accordance with a further aspect of the present invention there is provided a plant for processing spend potliners after use in the aluminium smelting process using the method described above.
DESCRIPTION OF THE DRAWINGS
Figure I is a block diagram that illustrates the flow chart to treat spent potliner, Figure 2 is a detailed flow chart of a detoxification process that forms part of the process illustrated in Figure 1, and Figure 3 is a schematic view of the process plant.
DESCRIPTION OF THE PREFERRED EMBODIMENT
An outline of the process for treating a spent potliner (SPL) of an aluminium smelter and producing a mineral product is shown in Figure 1 in three main steps, namely, (1) feed preparation in which the spent potliner is prepared crushed and classified, (2) detoxification in which the material is heated in the presence of air to destroy the presence of cyanide and mixed with water to cause neutralisation of reactive materials, and (3) a blending step in which treated SPL is mixed with other materials to produce mineral products of particular specifications which can be reused.
The feed preparation step involves recovery of the SPL material either from a storage depot or directly from the smelter pots, primary segregation of aluminium metal, carbon material and refractory materials and crushing size classification and secondary segregation of the materials into like categories. The crushing and classification steps are conventional to those skilled in this art.
Initially classified SPL is fed to the process plant. The sizing of the feed material can vary but -typically falls in the range 50 microns to 20mm.
The detoxification step involves a destruction of most of the cyanide through heat and then neutralisation 5 of the reactive compounds using water. The blending step producing mineral products takes place by blending the detoxified materials with other minerals and chemicals to achieve the desired product specification.
The detoxification process that is shown in detail in the flow summary of Figure 2 eliminates or substantially reduces the health environmental and explosive hazards that would otherwise be present in SPL.
The process involves a destruction of cyanide and the neutralisation of reactive compounds that give off acetylene, ammonia, methane, hydrogen and other gases. In the process described below it is understood that many of the requirements such as the heating temperatures and retention times would vary with different types of SPL
material.
The purpose of detoxofication is:
i) to convert as much as possible of the metal and metal compounds to inert oxides - eg.
4 Al + 3 02 - 2 A1203 A14C3 + 6 02 - 2 A1203 + 3 C02 4 Na4Fe (CN) 6 + 35 02 3 8 Na202 + 2 Fe203 + 24 CO2 + 12 N2 ii) destroy cyanides and combustible gases - eg.
Cyanide to carbon dioxide & nitrogen C2N2 + 2 02 4 2 CO2 + N2 Methane to carbon dioxide and water CH4 + 2 02 - CO2 + 2 H2O
Ammonia to nitrogen and water 4 NH3 + 3 02 4 2 N2 + 6 H2O
Hydrogen to water 2 H2 + 02 =3 2 H2O
The degree to which aluminium metal is oxidised depends upon the particle size, as a protective coating of the oxide inhibits instantaneous oxidation.
The neutralisation process involves the aqueous quenching of the hot product from the kiln to accelerate the reaction of any remaining metallic aluminium with its caustic environment. This part of the process also sees the reaction of any unoxidised carbides and nitrides as well as (protective) aluminium oxide. Eg.
2 Al + 2 OH- + 2 H2O 3 2 A102- + 3 H2 A14C3 + 12 H2O 3 4 Al(OH)3 + 3 CH4 CaC2 + 2 H2O -* Ca(OH)2 + C2H2 2 Al N + 6 H2O 3 2 Al(OH)3 + 2 NH3 Al(OH)3 + OH- -~ A102 - + 2 H2O
Gas evolution testing is carried out on the curing product to verify completion of explosive gas generation.
The potentially dangerous cyanide is destroyed by heating the SPL material in the presence of oxygen preferably to a range of between 750 C to 800 C. The heated SPL is held at that temperature for about 40 minutes. It is however important that the classified SPL
is not over heated to a temperature at which fluorides in the material enter the gaseous phase. This typically occurs at temperatures about 850 C and above.
A typical process plant is schematically shown in Figure 3. The classified SPL is initially fed to a belt feeder 10 which in turn feeds a bucket elevator 11 that transfers the SPL to a feed screw 12 that communicates with the inlet 13 of an elongate rotary kiln 20. A bag house dust collector 30 is in communication with the belt feeder and bucket elevator to control dust. The bag house dust collector would also include a source of cooling air 33. Agglomeration control air jets 21, 22 are positioned at either end of the kiln 20 and air is also fed to a probe support cooling jet 25. After leaving the kiln 30 the hot material is passed to a hydro-reaction mixer 40 where it is mixed with water. The product of the hydro-reaction mixer is then stock piled in a moist condition for curing in ambient air resulting in the detoxified material ready for reuse at the end of the ventilated curing step.
The classified SPL is heated to the required temperature in the rotary kiln 20 and the retention time in the material can be varied by varying the rotational speed of the kiln. The kiln 20 is usually fired by a fossil fuel burner and fuels could be natural petroleum gas, oil, pulverised coal or similar fuels. Additional air is introduced to the kiln to ensure that there is an oxygen rich environment in the kiln to support the chemical breakdown of cyanide. The temperature in the kiln is closely monitored with a number of thermocouple temperature probes located in the bed of material passing through the kiln 20. The temperature probes are mounted on a stainless steel tube through which air is blown from a compressed air source. Blowing air through the tube serves three purposes, namely (a) keeping the tube cool so that its structural integrity is maintained in the hot kiln environment, (b) keeping the signal cables from the thermocouple temperature probes cool in the otherwise hot environment in the kiln, and (c) introducing oxygen near the bed at points along the length of the kiln.
Some classified SPL materials have a tendency to agglomerate in the rotary kiln. This can occur at the feed end 13 when slightly damp material may build up and at points along the kiln where rings form as a result of heat causing certain minerals to enter a liquid phase.
Agglomeration is prevented by the agglomeration control jets 21, 22 which direct air from a compressed air source to points where agglomeration may occur. At the feed end 13 the jet of compressed air blows any material that sticks to the kiln lining off the kiln lining.
At points along the kiln where mineral in a liquid phase sticks to the kiln lining starting the formation of undesirable rings compressed air from an agglomeration control jet cools any liquid material returning it to a solid phase. The air jet 25 also cools the refractory lining at that location stopping the formation of liquid material against the hot refractory.
The agglomeration control jets 21, 22 provide additional free oxygen in the kiln to support the breakdown of cyanide.
The agglomeration control jets 21, 22 are mounted on a stainless steel pipe inside the kiln 20. The compressed air flowing through the pipe cools the pipe thus maintaining its structural integrity in the same manner as for the tube upon which the kiln temperature probes are mounted.
The reactive compounds that come out of the kiln are neutralised in two stages. In the first stage, known as the hydro-reaction stage, the hot 300 C to 500 C SPL
material is mixed with water 5 C to 20 C. The hot material from the kiln drops into a screw mixer. Water is sprayed into the mixer. The water reacts with the hot material from the kiln giving off steam and reaction gases such as acetylene, ammonia, hydrogen and methane. The thermal shock resulting from the hot solid mineral material coming into contact with the water, which is at a much lower temperature, causes surface fracturing of the mineral material. The surface fracturing increases the surface area of the mineral particles for the reaction with water, thus enhancing the process. This is the hydro-reaction process.
The reaction gases are passed through a flame to ensure that flammable gases are destroyed and to use the calorific value of those gases to assist in heating the classified SPL. Most of the reactive gases are given off in this first stage. Samples of the product from this stage are tested for cyanide and reactive compounds.
The second stage of neutralisation is ventilated curing and occurs over a period of up to four weeks.
Ventilated curing involves mixing the product from the first neutralisation stage of ambient temperature with water 5 C to 20 C in a well ventilated area. A stockpile of material is mixed with water in a well ventilated area using a front end loader. The stockpile is then left to cure in the well ventilated area. During this time a small amount of reactive gases are given off. The loader mixing process typically involves ten minutes of loader mixing for a 50 tonne stockpile of material. The mixing loader mixing takes place on a daily cycle for five to six days of each calendar week. Progressive samples are taken and tested for reactive compounds.
Environmental control of the plant is achieved by passing the process gas through the baghouse dust filter 30. The hot gases from the heating and hydro-reaction processes are mixed with atmospheric air to cool the process gas to the range of between 100 to 120 C. The cooled gas is then passed through a baghouse filter 30 to remove mineral dust from the exhaust gas. The mineral dust is returned to the process plant.
The cured residue that comes from the process described above can then be blended with a number of other materials to produce products that can be sold back to industry particularly for use as a fluxing agent in high temperature processes.
Aluminium smelter by-products are a primary source of raw material for manufacturing a range of industrial mineral and fuel products. The smelter raw materials are supplemented with a relatively small quantity of other raw materials sources externally from the smelter. The smelter mineral by-products are treated with sizing, classification and detoxification processes.
Industrial mineral and fuel products are then made by blending the treated smelter materials with the other externally sourced minerals and chemicals to achieve required product specifications.
The aluminium smelter by-products are:
Spent potliner (SPL) -Carbon SPL is the carbon cathode lining removed from reduction pots.
- Refractory SPL is the refractory lining of the pots that protects the cathode carbon lining.
Anode butt carbon - the carbon material cleaned from used anodes (anode butts).
Waste carbon - petroleum coke and other waste carbon from floor sweepings, dust filters and other areas of the aluminium smelter that capture waste carbon.
Bake furnace refractory - the refractory material lining material from the furnaces used to bake carbon anodes.
Waste alumina - alumina that has become contaminated with foreign material such that it is not able to be used as a raw material in the aluminium smelting process.
Aluminium dross fines - dross material recovered from the aluminium casting process that has high contents of alumina, sodium and fluorides.
Externally sourced raw materials are:
Black coal - for supplementary carbon.
Brown coal - for supplementary carbon.
Sand - for supplementary silica.
By careful blending and control of the consistencies three useful products have been produced that are sold under the trade marks Hi Cal 50, Hi Cal 60 and ReAl 14.
Technical details of each product are listed hereunder:
PRODUCT Hi Cal 50 Carbon fuel with high calorific value. Suitable for use in kilns, boilers, furnaces and rotary dryers.
The presence of fluorides and sodium may result in a beneficial mineralization or fluxing effect that reduces firing temperature in manufacture of products such as cement and bricks.
Chemical Analysis Aluminium as A1203 12 to 15% }
Calcium as CaO 1 to 3% }
Iron as Fe203 3 to 6% }
Sodium as Na20 8 to 12% } X-ray Potassium as K20 0.3 to 0.6% } Fluorescence Silicon as Si02 8 to 12% }
Sulphur as S 03 0.5 to 1.0% }
Carbon (total) 50 to 55% }
Fluoride (total) 8 to 12% - Pyrohydrolysis /
Ion Chromatography Fluoride (Leachable) <2500mg/l - Water Soluble Anions / Ion Chromatography Trace Element Analysis Mercury Hg <0.03 mg/kg } Coal Vapour Atomic Absorption Spectrometry Arsenic As <15 mg/kg } Eschka Fusion Method/Hydride Selenium Se <2 mg/kg } Inductive Coupled Plasma Antimony Sb <3 mg/kg } Spectrometry Manganese Mn <250 mg/kg } Slow Ash Fusion /
Nickel Ni <100 mg/kg } Inductive Coupled Plasma Chromium Cr <70 mg/kg } Spectrometry or Atomic Copper Cu <315 mg/kg } Absorption Spectrometry Vanadium V <80 mg/kg }
Cobalt Co <30 mg/kg }
Beryllium Be <10 mg/kg }
Tin Sn <30 mg/kg }
Lead Pb <80 mg/kg }
material is mixed with water 5 C to 20 C. The hot material from the kiln drops into a screw mixer. Water is sprayed into the mixer. The water reacts with the hot material from the kiln giving off steam and reaction gases such as acetylene, ammonia, hydrogen and methane. The thermal shock resulting from the hot solid mineral material coming into contact with the water, which is at a much lower temperature, causes surface fracturing of the mineral material. The surface fracturing increases the surface area of the mineral particles for the reaction with water, thus enhancing the process. This is the hydro-reaction process.
The reaction gases are passed through a flame to ensure that flammable gases are destroyed and to use the calorific value of those gases to assist in heating the classified SPL. Most of the reactive gases are given off in this first stage. Samples of the product from this stage are tested for cyanide and reactive compounds.
The second stage of neutralisation is ventilated curing and occurs over a period of up to four weeks.
Ventilated curing involves mixing the product from the first neutralisation stage of ambient temperature with water 5 C to 20 C in a well ventilated area. A stockpile of material is mixed with water in a well ventilated area using a front end loader. The stockpile is then left to cure in the well ventilated area. During this time a small amount of reactive gases are given off. The loader mixing process typically involves ten minutes of loader mixing for a 50 tonne stockpile of material. The mixing loader mixing takes place on a daily cycle for five to six days of each calendar week. Progressive samples are taken and tested for reactive compounds.
Environmental control of the plant is achieved by passing the process gas through the baghouse dust filter 30. The hot gases from the heating and hydro-reaction processes are mixed with atmospheric air to cool the process gas to the range of between 100 to 120 C. The cooled gas is then passed through a baghouse filter 30 to remove mineral dust from the exhaust gas. The mineral dust is returned to the process plant.
The cured residue that comes from the process described above can then be blended with a number of other materials to produce products that can be sold back to industry particularly for use as a fluxing agent in high temperature processes.
Aluminium smelter by-products are a primary source of raw material for manufacturing a range of industrial mineral and fuel products. The smelter raw materials are supplemented with a relatively small quantity of other raw materials sources externally from the smelter. The smelter mineral by-products are treated with sizing, classification and detoxification processes.
Industrial mineral and fuel products are then made by blending the treated smelter materials with the other externally sourced minerals and chemicals to achieve required product specifications.
The aluminium smelter by-products are:
Spent potliner (SPL) -Carbon SPL is the carbon cathode lining removed from reduction pots.
- Refractory SPL is the refractory lining of the pots that protects the cathode carbon lining.
Anode butt carbon - the carbon material cleaned from used anodes (anode butts).
Waste carbon - petroleum coke and other waste carbon from floor sweepings, dust filters and other areas of the aluminium smelter that capture waste carbon.
Bake furnace refractory - the refractory material lining material from the furnaces used to bake carbon anodes.
Waste alumina - alumina that has become contaminated with foreign material such that it is not able to be used as a raw material in the aluminium smelting process.
Aluminium dross fines - dross material recovered from the aluminium casting process that has high contents of alumina, sodium and fluorides.
Externally sourced raw materials are:
Black coal - for supplementary carbon.
Brown coal - for supplementary carbon.
Sand - for supplementary silica.
By careful blending and control of the consistencies three useful products have been produced that are sold under the trade marks Hi Cal 50, Hi Cal 60 and ReAl 14.
Technical details of each product are listed hereunder:
PRODUCT Hi Cal 50 Carbon fuel with high calorific value. Suitable for use in kilns, boilers, furnaces and rotary dryers.
The presence of fluorides and sodium may result in a beneficial mineralization or fluxing effect that reduces firing temperature in manufacture of products such as cement and bricks.
Chemical Analysis Aluminium as A1203 12 to 15% }
Calcium as CaO 1 to 3% }
Iron as Fe203 3 to 6% }
Sodium as Na20 8 to 12% } X-ray Potassium as K20 0.3 to 0.6% } Fluorescence Silicon as Si02 8 to 12% }
Sulphur as S 03 0.5 to 1.0% }
Carbon (total) 50 to 55% }
Fluoride (total) 8 to 12% - Pyrohydrolysis /
Ion Chromatography Fluoride (Leachable) <2500mg/l - Water Soluble Anions / Ion Chromatography Trace Element Analysis Mercury Hg <0.03 mg/kg } Coal Vapour Atomic Absorption Spectrometry Arsenic As <15 mg/kg } Eschka Fusion Method/Hydride Selenium Se <2 mg/kg } Inductive Coupled Plasma Antimony Sb <3 mg/kg } Spectrometry Manganese Mn <250 mg/kg } Slow Ash Fusion /
Nickel Ni <100 mg/kg } Inductive Coupled Plasma Chromium Cr <70 mg/kg } Spectrometry or Atomic Copper Cu <315 mg/kg } Absorption Spectrometry Vanadium V <80 mg/kg }
Cobalt Co <30 mg/kg }
Beryllium Be <10 mg/kg }
Tin Sn <30 mg/kg }
Lead Pb <80 mg/kg }
Cadmium Cd <2 mg/kg - Graphite Atomic Absorption Spectrometry Chlorine Cl <0.01 % - Pyrohydrolysis / Ion Chromatography Cyanide Cn <100 mg/kg - Iron selective Electrode (ISE) Cyanide Cn <0.2 mg/l - Iron selective Electrode (Leachable) (ISE) PRODUCT Hi Cal 60 Carbon fuel with high calorific value. Suitable for use in kilns, boilers, furnaces and rotary dryers.
The presence of fluorides and sodium may result in a beneficial mineralization or fluxing effect that reduces firing temperature in manufacture of products such as cement and bricks.
Chemical Analysis Aluminium as A1203 4 to 8% }
Calcium as CaO 1 to 3% }
Iron as Fe203 1 to 3% }
Sodium as Na20 5 to 8% } X-ray Potassium as K20 0.2 to 0.4% } Fluorescence Silicon as Si02 1 to 3% }
=30 Sulphur as S 03 0.5 to 1.0% }
Carbon (total) 60 to 65% }
Fluoride (total) 4 to 8% - Pyrohydrolysis /
Ion Chromatography Fluoride (Leachable) <1000mg/l - Water Soluble Anions / Ion Chromatography Trace Element Analysis Mercury Hg <0.03 mg/kg } Coal Vapour Atomic Absorption Spectrometry Arsenic As <15 mg/kg } Eschka Fusion Method/Hydride Selenium Se <2 mg/kg } Inductive Coupled Plasma Antimony Sb <3 mg/kg } Spectrometry Manganese Mn <250 mg/kg } Slow Ash Fusion /
Nickel Ni <100 mg/kg } Inductive Coupled Plasma Chromium Cr <70 mg/kg } Spectrometry or Atomic Copper Cu <315 mg/kg } Absorption Spectrometry Vanadium V <80 mg/kg }
Cobalt Co <30 mg/kg }
Beryllium Be <10 mg/kg }
Tin Sn <30 mg/kg }
Lead Pb <80 mg/kg }
Cadmium Cd <15 mg/kg - Graphite Atomic Absorption Spectrometry Sulphur S <8 % - Pyrohydrolysis /
Titration Chloride Cl <0.01 $ - Pyrohydrolysis / Ion Chromatography Cyanide Cn <60 mg/kg - Iron selective Electrode (ISE) Cyanide Cn <0.2 mg/l - Iron selective Electrode (Leachable) (ISE) PRODUCT ReAl 14 Mineral additive with high alumina and silica value. Suitable for use in the manufacture of cement, refractory and bricks. The presence of fluorides and sodium may result in a beneficial mineralization or fluxing effect that reduces firing temperature in manufacture of products such as cement and bricks.
Chemical Analysis Aluminium as A1203 14 to 18% }
Calcium as CaO 2 to 4% }
Iron as Fe203 3 to 5% }
Sodium as Na20 18 to 22% } X-ray Potassium as K20 1 to 2% } Fluorescence Silicon as Si02 35 to 38% }
Sulphur as S 03 0.5 to 1.0% }
Fluoride (total) 8 to 12% - Pyrohydrolysis /
Ion Chromatography Fluoride (Leachable) <2200mg/l - Water Soluble Anions / Ion Chromatography Trace Element Analysis Mercury Hg <0.03 mg/kg } Coal Vapour Atomic Absorption Spectrometry Arsenic As <10 mg/kg } Eschka Fusion Method/Hydride Selenium Se <1 mg/kg } Inductive Coupled Plasma Antimony Sb <2 mg/kg } Spectrometry Manganese Mn <450 mg/kg } Slow Ash Fusion /
Nickel Ni <50 mg/kg } Inductive Coupled Plasma Chromium Cr <70 mg/kg } Spectrometry or Atomic Copper Cu <50 mg/kg } Absorption Spectrometry Vanadium V <90 mg/kg }
Cobalt Co <50 mg/kg }
Beryllium Be <8 mg/kg }
Tin Sn <5 mg/kg }
Lead Pb <50 mg/kg }
Cadmium Cd <15 mg/kg - Graphite Atomic Absorption Spectrometry Chloride C1 <0.01 % - Pyrohydrolysis / Ion Chromatography Cyanide Cn <60 mg/kg - Iron selective Electrode (ISE) Cyanide Cn <0.2 mg/1 - Iron selective Electrode (Leachable) (ISE)
The presence of fluorides and sodium may result in a beneficial mineralization or fluxing effect that reduces firing temperature in manufacture of products such as cement and bricks.
Chemical Analysis Aluminium as A1203 4 to 8% }
Calcium as CaO 1 to 3% }
Iron as Fe203 1 to 3% }
Sodium as Na20 5 to 8% } X-ray Potassium as K20 0.2 to 0.4% } Fluorescence Silicon as Si02 1 to 3% }
=30 Sulphur as S 03 0.5 to 1.0% }
Carbon (total) 60 to 65% }
Fluoride (total) 4 to 8% - Pyrohydrolysis /
Ion Chromatography Fluoride (Leachable) <1000mg/l - Water Soluble Anions / Ion Chromatography Trace Element Analysis Mercury Hg <0.03 mg/kg } Coal Vapour Atomic Absorption Spectrometry Arsenic As <15 mg/kg } Eschka Fusion Method/Hydride Selenium Se <2 mg/kg } Inductive Coupled Plasma Antimony Sb <3 mg/kg } Spectrometry Manganese Mn <250 mg/kg } Slow Ash Fusion /
Nickel Ni <100 mg/kg } Inductive Coupled Plasma Chromium Cr <70 mg/kg } Spectrometry or Atomic Copper Cu <315 mg/kg } Absorption Spectrometry Vanadium V <80 mg/kg }
Cobalt Co <30 mg/kg }
Beryllium Be <10 mg/kg }
Tin Sn <30 mg/kg }
Lead Pb <80 mg/kg }
Cadmium Cd <15 mg/kg - Graphite Atomic Absorption Spectrometry Sulphur S <8 % - Pyrohydrolysis /
Titration Chloride Cl <0.01 $ - Pyrohydrolysis / Ion Chromatography Cyanide Cn <60 mg/kg - Iron selective Electrode (ISE) Cyanide Cn <0.2 mg/l - Iron selective Electrode (Leachable) (ISE) PRODUCT ReAl 14 Mineral additive with high alumina and silica value. Suitable for use in the manufacture of cement, refractory and bricks. The presence of fluorides and sodium may result in a beneficial mineralization or fluxing effect that reduces firing temperature in manufacture of products such as cement and bricks.
Chemical Analysis Aluminium as A1203 14 to 18% }
Calcium as CaO 2 to 4% }
Iron as Fe203 3 to 5% }
Sodium as Na20 18 to 22% } X-ray Potassium as K20 1 to 2% } Fluorescence Silicon as Si02 35 to 38% }
Sulphur as S 03 0.5 to 1.0% }
Fluoride (total) 8 to 12% - Pyrohydrolysis /
Ion Chromatography Fluoride (Leachable) <2200mg/l - Water Soluble Anions / Ion Chromatography Trace Element Analysis Mercury Hg <0.03 mg/kg } Coal Vapour Atomic Absorption Spectrometry Arsenic As <10 mg/kg } Eschka Fusion Method/Hydride Selenium Se <1 mg/kg } Inductive Coupled Plasma Antimony Sb <2 mg/kg } Spectrometry Manganese Mn <450 mg/kg } Slow Ash Fusion /
Nickel Ni <50 mg/kg } Inductive Coupled Plasma Chromium Cr <70 mg/kg } Spectrometry or Atomic Copper Cu <50 mg/kg } Absorption Spectrometry Vanadium V <90 mg/kg }
Cobalt Co <50 mg/kg }
Beryllium Be <8 mg/kg }
Tin Sn <5 mg/kg }
Lead Pb <50 mg/kg }
Cadmium Cd <15 mg/kg - Graphite Atomic Absorption Spectrometry Chloride C1 <0.01 % - Pyrohydrolysis / Ion Chromatography Cyanide Cn <60 mg/kg - Iron selective Electrode (ISE) Cyanide Cn <0.2 mg/1 - Iron selective Electrode (Leachable) (ISE)
Claims (8)
1. A method of treating a spent potliner after use in an aluminium smelting process, the method comprising crushing and classifying the spent potliner, placing the classified and crushed spent potliner in a furnace at a temperature greater than 450°C, heating the spent potliner to a temperature greater than 450°C, mixing the heated spent potliner with water to neutralize reactive compounds in the spent pot liner, and produce reaction gases and residue, burning the reaction gases, mixing the residue with water in a well ventilated area for a period of weeks to cure the residue, and blending the cured residue with other chemicals and minerals to provide useful mineral products.
2. The method according to claim 1 wherein the classified and crushed spent potliner is positioned in a rotary kiln into which air is introduced to ensure an oxygen enriched environment.
3. The method according to claim 2 comprising using thermocouples to control the temperature of the kiln.
4. The method according to claim 2 comprising directing jets of air into the kiln to prevent agglomeration.
5. The method according to claim 1 comprising exposing the wet mixture in a pile to ambient conditions between 5 and 20°C in a well ventilated location.
6. The method according to claim 5 comprising mixing the pile on a daily basis with total exposure being up to four weeks.
7. A plant for processing spent potliners according to the method of claim 1.
8. Mineral products comprising chemicals and minerals blended with residue treated by the method in accordance with claim 1.
Applications Claiming Priority (3)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
AU2002952159A AU2002952159A0 (en) | 2002-10-18 | 2002-10-18 | Treatment of Smelting By-Products |
AU2002952159 | 2002-10-18 | ||
PCT/AU2003/001390 WO2004035238A1 (en) | 2002-10-18 | 2003-10-20 | Treatment of smelting by-products |
Publications (2)
Publication Number | Publication Date |
---|---|
CA2502498A1 CA2502498A1 (en) | 2004-04-29 |
CA2502498C true CA2502498C (en) | 2011-09-20 |
Family
ID=28047724
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
CA 2502498 Expired - Lifetime CA2502498C (en) | 2002-10-18 | 2003-10-20 | Treatment of smelting by-products |
Country Status (9)
Country | Link |
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US (1) | US7594952B2 (en) |
EP (1) | EP1551573B1 (en) |
AU (2) | AU2002952159A0 (en) |
CA (1) | CA2502498C (en) |
ES (1) | ES2661928T3 (en) |
NO (1) | NO342500B1 (en) |
NZ (1) | NZ539590A (en) |
WO (1) | WO2004035238A1 (en) |
ZA (1) | ZA200502879B (en) |
Families Citing this family (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US20110081284A1 (en) * | 2009-10-02 | 2011-04-07 | Mark Weaver | Treatment of bauxite residue and spent pot lining |
CN110015672B (en) * | 2019-05-24 | 2021-06-18 | 郑州大学 | Method for producing magnesium fluoride by using electrolytic cell waste |
CA3172680A1 (en) * | 2020-03-22 | 2021-09-30 | Jean-Rene Gagnon | Plasma process to convert spent pot lining (spl) to inert slag, aluminum fluoride and energy |
Family Cites Families (6)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US4355017A (en) * | 1981-05-14 | 1982-10-19 | Martin Marietta Corporation | Aluminum electrolytic cell cathode waste recovery |
US4444740A (en) | 1983-02-14 | 1984-04-24 | Atlantic Richfield Company | Method for the recovery of fluorides from spent aluminum potlining and the production of an environmentally safe waste residue |
US4900535A (en) * | 1986-12-22 | 1990-02-13 | Comalco Aluminum Limited | Recovery of fluoride values from waste materials |
CA2097809A1 (en) | 1991-01-11 | 1992-07-12 | David Hughes Jenkins | Recovery of aluminium and fluoride values from spent pot lining |
WO1992020469A1 (en) * | 1991-05-16 | 1992-11-26 | Qubator Pty Limited | Process for converting spent pot liner |
CA2159806C (en) | 1993-04-06 | 2005-07-05 | John Millice Floyd | Smelting of carbon-containing material |
-
2002
- 2002-10-18 AU AU2002952159A patent/AU2002952159A0/en not_active Abandoned
-
2003
- 2003-10-20 AU AU2003271428A patent/AU2003271428B2/en not_active Expired
- 2003-10-20 NZ NZ539590A patent/NZ539590A/en not_active IP Right Cessation
- 2003-10-20 US US10/531,835 patent/US7594952B2/en active Active
- 2003-10-20 ES ES03753137.3T patent/ES2661928T3/en not_active Expired - Lifetime
- 2003-10-20 EP EP03753137.3A patent/EP1551573B1/en not_active Expired - Lifetime
- 2003-10-20 WO PCT/AU2003/001390 patent/WO2004035238A1/en active IP Right Grant
- 2003-10-20 CA CA 2502498 patent/CA2502498C/en not_active Expired - Lifetime
-
2005
- 2005-04-08 ZA ZA2005/02879A patent/ZA200502879B/en unknown
- 2005-05-12 NO NO20052326A patent/NO342500B1/en not_active IP Right Cessation
Also Published As
Publication number | Publication date |
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US20060053973A1 (en) | 2006-03-16 |
ZA200502879B (en) | 2005-12-28 |
NO342500B1 (en) | 2018-06-04 |
EP1551573A4 (en) | 2011-01-26 |
NZ539590A (en) | 2006-11-30 |
AU2003271428B2 (en) | 2007-05-31 |
EP1551573B1 (en) | 2017-12-06 |
NO20052326L (en) | 2005-07-11 |
NO20052326D0 (en) | 2005-05-12 |
ES2661928T3 (en) | 2018-04-04 |
AU2002952159A0 (en) | 2002-10-31 |
AU2003271428A1 (en) | 2004-05-04 |
US7594952B2 (en) | 2009-09-29 |
CA2502498A1 (en) | 2004-04-29 |
EP1551573A1 (en) | 2005-07-13 |
WO2004035238A1 (en) | 2004-04-29 |
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